Machine for packaging cartons



Aug. 2, 1960 H. w. WILSON T AL 2,947,125

MACHINE FOR PACKAGING CARTONS Filed April 29, 1957 '7 Sheets-Sheet 1 3 L 8 BY (fig l7 Z 0250 Aug. 2, 1960 H. W. WILSON ET AL MACHINE FOR PACKAGING CARTONS '7 Sheets-Sheet 2 Filed April 29, 1957 AJIWXZVEY Aug. 2, 1960 H. w. WILSON ETAI- 2,947,125

MACHINE FOR PACKAGING CARTONS Filed April 29, 1957 v Sheets+Sheet s F'/s.5 69 D INVENTORS xmfiy w w/zsa/v 55 cu/vra/v L. aways/4 5.2 @MQM 53 ArJmA/H Aug. 2, 1960 H. w. WILSON ETAI- 2,947,125

MACHINE FOR PACKAGING CARTONS 7 Sheets-Sheet 4 Filed April 29, 1957 INVENTORS AMAAY m W/zm/v BY cz/A/m/v z. 0053:

Azmmz' Aug. 2, 1960 HAW. WILSON E 2,947,125

MACHINE FOR PACKAGING CARTONS Filed April 29, 1957 '7 Sheets-Sheet 5 INVENTORS AAKKY W. W/LJfl/ /60 CL/NM/V L. oak/mus Aug. 2, 1960 H. w. WILSON ETAL 2,947,125

' MACHINE FOR PACKAGING CARTONS 7 Sheets-Sheet 6 Filed April 29, 1957 5 5 an mm W MN x 00A a W N L mh RN Y N Mm M 0 r -mm Q M N QNN N3 1 M Q \NN RN N H M N-J ed States P en MACHINE FOR PACKAGING CARTONS Harry W. Wilson, Millbrae, and Clinton L. Dornbush, Palo Alto, Calif., assignors to Royal Container Co., San Francisco, Calif., a corporation of California 'Filed Apr. 29, 1957, SenNo. 655,774

40 Claims. on. 53-61) This invention relates to a method and apparatus for packaging collapsed cartons.

Corrugated paper boxes and cartons are commonly shipped from the manufacturers to the users in the collapsed form known in industry terminology as k.d.f., meaning knocked-down-fiat. At this k.d.f. stage, the carton blanks have been properly slotted, scored and folded, and the two end panels have been glued or otherwise connected by methods that are conventional in the industry, so that all the user has to do is to open the k.d.f. carton out and fold over the bottom and top flaps.

However, the shipping of k.d.f. cartons has presented a hitherto 'unsolved packaging problem to which the present invention is directed. The method most general in the prior art has been to tie wire or twine around a small stack of about 25 cartons, forming a tied bundle.

The bundles have then either been packed entirely by hand, which is costly, or a number of bundles have been stacked by hand on wooden pallets of the so-called returnable type, for handling by fork-lift trucks. Returnable pallets, however, are expensive to use, not only because of the material cost but also because of the necessity for recording their whereabouts, constantly maintaining them in proper condition, and returning them to the shipper. The shipper must maintain a considerable investment in pallets if he is to have enough on hand for each shipment, because, at any one time, many pallets are at the customers warehouses or are in trucks en route to the customers. Also, pallets are often lost or broken in shipment. He'retofore, non-returnable pallets have been still more expensive in the long run and have not been used to any great extent.

Another problem has been that standard pallets usually do not conform to the dimensions of the bundled cartons; so when the cartons were stacked on the pallets they either failed to fill the surface of the pallet or overhung the edges. it was not possible when using standard pallets to put the maximum number of cartons into the shipping spaces available in rail cars or trucks. Moreover, a great variety of box sizes are used, each size remaining difierent r 2,947,125 ICC g nt d Aug. 2,1960

' that the cartons stand on edge and are held under pressure during strapping so that all the air is squeezed out and the surfaces made equiplanar. All this is explained in the applications referred to. The self-palletized bale from cartons that are too small to be handled in a single In either event, space was wasted and when the boxes are knocked down flat, so that it was only coincidence when the pallet size and the box size coincided. For the same reason, much space is lost in warehouses when storing boxes on pallets.

The inconvenience of these prior-art packaging methods has been overcome by an invention by Harry W. Wilson, described in his application Serial No. 592,185, filed June 18, 1956, for a self-palletized package. In that invention the bale is formed by strapping together a sufiicient number of cartons to make, when compressed and secured together, a bundle or bale one-half the width of a truck or rail car. The finished self-palletized bale is characterized by resting on a pair of runners that formed an integral part of the package, being held to the package by the same steel straps that hold the bale together. Also, the 'self-palletized bale is characterized by the fact stack by fork-lift trucks, i.e. where there is not enough room to provide entry space for the forks, which are usually about 28" to 32" apart. This important result is accomplished by a novel double stack of the' smaller cartons, joinedonly by locking sheets (or cap sheets, as they are sometimes called) that are strapped into 'the bale. By pitting against each other, through the locking sheets, those forces that tend to cause the bale to come apart, the bale can be held together by flanged locking sheets of corrugated paper. The high shear or 'tensile strength of sheet material when subjected to stretching, is availed of in a novel manner fully explained in the aboveidentified continuation-impart application.

In any event, when this improved bale was first introduced, the stacking had to be done by hand and the entire operation had to be done on a batch-basis, usually by two men. It involved a lot of hard work and manual" labor. It was difiicult for hand labor in the packaging stage to keep up with modern carton production machines, which can produce a hundred thousand k.d.f. cartons in an eight-hour day. One object 'of the present invention is to solve this packaging problem by providing a method anda pparatus which greatly simplify the packaging of k.d.f. boxes into self-palletized bales, or other convenient types of packages. i Another object of the invention is to providea rapid package-production machine employing a novel method, which automatically forms large stacks from small ones. Another object is to provide apparatus that automatically advances the large stacks after a certain number of small stacks has been incorporated into it. 7 i

Another object is to enable the rapid and economical formation of large stacks of k.'d.f. cartons into secured packages, with or without a self-palletizing construction. Another object is to provide a novel press for baling k.d.f. cartons.

Another object of the invention is to provide an automatic unloading device, which automatically organizes the packages into groups of self-palleti'zed bales embodying four or more large stacks, two stacks on a bottom layer and two or more on one or more upper layers all supported on one set of boards, so as to save materials, especially cap sheets and pallet'boards. i

Another object of the invention is to make it possible to package, ona single machine, the production of the converting machines k.d.f. boxes in an' eight-hour day, without difficulty. v

Another object of the invention is to provide a series of safety switches, safety interlocks, and other safeguards for producing packages of k.d.f. cartons with safety to personnel and equipment. 7

Another object of the invention is to provide means for straightening the packages as they are produced.

means for preventing advancement from one stage of the operation to another, until the succeeding stage has been cleared by advancement therefrom.

Another object of the invention is to provide an integrated machine for packaging k.d.f. cartons in large bales.

Another object is to provide a machine in which certain operations that are done more efficiently manually than by machine are so done and in which the controls for the automatic portions are integrated with the manual controls to unify the packaging system.

Other objects and advantages of the invention will appear from the following description of a preferred embodiment.

In the drawings:

Fig. 1 is a view in side elevation of a machine embodying the principles of the invention and shown on two sheets because of the length of the machine, Fig. la showing the first part of the machine, reading from right to left, with a partly stacked package in the stacker, and two stacked packages in the accumulator, the outer end of the conveyor into the machine being cut off, and some parts being broken away to show other parts, while Fig. lb is a continuation from the left-hand end of Fig. 1a showing the remainder of the machine in side-elevation, with some parts broken away and with a partly stnapped bundle in the press.

Fig. 2 is a view in elevation of the stop gate at the entry to the stacker, shown in its open, depressed, position, in comparison with the closed, raised, position shown in Fig. 1.

Fig. 3 is a view in vertical section taken along the line 33 in Fig. la and showing the stacking portion of the device, with a partially completed stack therein and with some parts of the machine cut away.

Fig. 4 is a view in vertical section on an enlarged scale, taken along the line 44 in Fig. 1a and also showing a portion of the stacking device, but with the stack elevator raising a small stack through the horizontal gates, which are therefore shown in their open position instead of the closed position shown in Fig. 1a, where the stack elevator is in its lowered position.

Fig. 5 is a top plan view in horizontal section on the same scale as in Fig. 4, taken along the line 5-5 in Fig. 1a, also showing the stacking device, but with the ejector advanced about two-thirds of the way toward the end of its ejecting stroke to advance a completed stack into the accumulator. The vertical gates at the left end of the stacker are shown in solid lines in their open position, Where they are pushed by the stack of cartons being ejected, and broken lines indicate the normal, closed position of these gates.

Fig. 6 is a view in side elevation of the ejector, taken along the line 6-6 in Fig. 3 and showing the control switches thereon and the switch operating cam.

Fig. 7 is a view in vertical section taken along the line 7-7 in Fig. 1a, with some parts cut away to show the device with greater clarity. shows the accumulator station with stacks of k.d.f. cartons therein and a lower cap or locking sheet inserted between the bottom of the stack and the conveyor belts, the lower conveyor belts being shown in their lower, retracted position.

Fig. 8 is a view in section, taken along the line 88 in Fig. 1b, with some parts cut away, and showing the baling press, where the straps are applied. As in Fig. 1b, the stack of cartons is shown with one strap applied and one not yet applied.

Fig. 9 is a detail view of a portion of the baling press, shown on an enlarged scale in partial elevation and partly in section, and showing in solid lines the rollers in their retracted position and, in dot-dash lines, the same rollers in their raised, driving position.

Fig. 10 is a perspective view of the roller-supporting 4 carriages in the press with some parts cut away and other parts removed.

Fig. 11 is a view in section taken along the line 11- 11 in Fig. lb, and showing the bale unloader in three positions, the unloader being shown in solid ilnes in its normal, untipped position, and in broken lines in two of its tipping positions; one where it tips to receive the first layer of packages, and another where it empties a two-layer unit of packaged cartons onto a roller conveyor.

Fig. 12 is a top plan view of a portion of the unloading unit, with some parts cut away, shown as looking 7 down on Fig. 11.

In particular, Fig. 7

Fig. 13 is an electrical circuit diagram of the device.

General description of the method and device (Figs. 1a and 1b) The machine shown in the drawings is a multi-stage device, each stage being adapted to perform one or more steps in the method of this invention and being related to the other stages. In general, small stacks A of k.d.f. cartons B are placed on an introductory conveyor C, which leads into a stacking device D, where the small stacks A, usually about 25 k.d.f. cartons B each, are made into large stacks E many times as big, such as stacks of about to 200 cartons. The large stack E is then advanced by an ejector F into the next stage of operation, which may be called an accumulator G.v

In the accumulator G a first large stack E is held until a second similar stack E arrives. In those bales that are to be self-palletized, a single oversize bottom cap or locking sheet H may then be applied beneath the two stacks, E and E For most operations, it is advisable to add the cap sheet manually, though it may be added by automatic machinery.

When the operator has the bottom cap sheet H in place (if one is used) and at the proper time to advance the two stacks E and E he presses a button that sends them into press I while folding up the protruding sides of the cap sheet H to provide a pair of stabilizing flanges whose importance is explained in the referred-to applications. At the press I, the stacks E and E are compressed tightly together and baled with steel strapping (or baling wire, if preferred). In those instances where a self-palletized package is to be made, an additional locking sheet K and two pallet strips L are applied, and in all instances bumper strips M are applied, before the strap I, to protect the edges where the wire or strap I turns a corner. The baled and self-palletized package N is then advanced along a conveyor 0 to an unloading device P, where the bale N (which is purposely manufactured on-end) is tipped away from the conveyor 0 and, preferably after a second or third or fourth layer of bales is received, is unloaded to an unloading conveyor Q.

The operating sequence and detailed operation of the machine will be described after the following description of each stage or section thereof.

Introductory conveyor C (Fig. 1a)

be 25 cartons B in each stack A, or there may be more or fewer cartons in each stack A, the quantity being varied to suit the need. The stacks A reach the machine on the introductory conveyor C, which may comprise a frame 20, supporting a number of freely mounted rollers 21 at heights graduated to produce a gravity feed, the lowest roller 21 being at the intake end of the machine. Such conveyors C are well known in the art and need not be further illustrated; the gravity feed is preferred because some of the stacks are stopped before entering the, stacker D, but other types of feed may be used.

gains The stop gate 22 (Figs. 1a and '2) At the end of the introductory conveyor C, just beyond the last and lowest roller 21, is an electrically operated stop gate 22 controlling the entry of the stacks A so that only one stack A at a time can enter the stacker D. The stop gate 22 (see Fig.2) may comprise a vertical flange or strip 23 mounted at the outer end 'of an arm or strip 24. The arm24 may be pivotally mounted near its inner end on a pivot 25, journaled on the frame 35.. A crank arm 26 depends from the inner end of the arm 24, on the opposite side of the pivot 25 from the flange 23, and one end of a tension spring 27 is anchored to the crank 26. The other end of the spring 27 is .secured to the frame 20, and so pulls the crank arm 26 toward the frame 20,. thereby urging the stop gate 22 upto a normal elevated or stopping position, where carton stacks A will engage the flange 23, and be stopped from entering the stacker D.

A normallyde-energized solenoid 28 may be mounted on the frame 35 outboard from the pivot 25, with its core pivotally secured to the arm 24 and thereby adapted upon energization of the solenoid 28 to pull down the arm 24 and open the stop gate 22 so that a stack A can pass through. Upon later de-energizationby a switch 42 of the solenoid 28 the spring 27 pulls the stop gate 22 up again to where it will block the passage of the next carton stack A. The electric circuit that controls the stop gate 22 will be explained in connection with the stacking device D.

Feeding the stacks A into the stacker D (Figs. 1a and 3-5 From the stop gate 22, a small stack A is carried by a spaced-apart parallel pair of feed belts 30 and 31 into the stacker D. The belts 30 and 31 are continuous and are preferably mounted on respective drive rollers 32, secured to a common drive shaft 33, and idling rollers 34, on another shaft which may also be driven if desired. The shafts are preferably journaled in or otherwise' rotatably supported by a main stacker frame 35 .which may, if desired, be a portion of an overall main frame, or may be separate. The drive shaft 33-may be driven by a motor 36 through a chain 37. -The belts 30 and 31 convey each stack or bundle A from the stop gate 22, between two pairs of straightening guides 38 and, if desired, between two straightening rollers 38a, which are preferably driven, as by belt 38b at the same speed as the belts 30 and 31. In any event, it is important to form straight stacks. The belts 30, 31 convey the straightened stack A into the stacker D, where the bundle A is'stopped by -a pair of vertically extending rigid stop members 39 directly below a pair of vertically extending gates'40 and 41. The momentum .of the cartons B as they strike the stop members 39 solenoid 28to hold the stop' gate 22 open. The solenoid 28 being tie-energized, thespring 27 pulls the stop gate '22 up to prevent a second stack A from passing. Preferably, the switch 42 is located less than the length of a carton B from the stop gate 22, so that the stop gate 22 can separate an immediately adjacent stack A from the first stack A Separation is possible, it may be added,

gravity over the rollers 21, resulting ina gap between the stacks into which the flange 23 can move.

The stacker .frame and gates (Figs. 1a and 3-5) The vertical gates 40, 41 whose lower'ends lie above the upper ends of the stops 39, are pivoted on hinges 44 to respective vertical frame members 45 'of the stacker frame 35, and the gates 40, 41 are normally urged to their carton-stopping position transverse to the belts 30, 31 by strong springs 46. a

The stacker D also has rear vertical frame members 47 that extend parallel to the edges of the belts 30, 31'

and whose upper portions are' provided with transversely extending portions 48; Thus the gates 40,41 (with the stops 39) and frame members 45, 47' and-48 enclose and define the corners of a rectangular right prism, within which the boxes are stacked and by which they are kept aligned. There are no lower portions of the members 48, because if there were they would prevent entry of the cartons B into the stacker D.

A pair of normally horizontal gates 50, 51 are pivotally mounted on horizontal rods 52 level with the lower ends of the gates 40, 41 and the transverse frame members 48. The rods 52 are supported rotatably by brackets 53 on" the frame members 45 and 47, so that they can swing upwardly and outwardly as the stack A is raised in the manner described in the next section. Returnsprings 54 are secured between arms 55 on the horizontal gates 50, 51 and books 56 on the frames 45, to urge the gates 50, 51 to their normal position, while permitting them to lift and swing out to admit cartons from below. The outer ends 55a of the arms 55 serve as stops to prevent the gates 50, 51 from falling below their horizontal position.

The frames 47 may be made adjustable relative to each other and to the frame members 45 for accommodating different lengths and widths of k.d.f. cartons B, where that is desirable. Some of the adjustment features have been omitted from some of the drawings, where they would serve the cause of confusion more than the cause of clarity; after all, the man skilled in the art knows well how to provide such adjustability. Threaded rods 57, rails 58, and frame carriages 59 suffice to show the widthwise adjustability of the frame members, the upper and lower rods preferably being joined by chains 59a and rotated together by a handwheel 59b. Lengthwise adjustment is obtained by the carriage 59 and rails 59c.

'The stacker D and its stacking elevator 60 (Figs. 1a, 3 and 4) Directly below the area enclosed by the stacker frame is a stacking elevator 60, comprising a cylinder 61, a piston 62, and a platform 63 supported on the upper end of the piston 62. Upward movement of the piston 62 therefore causes the elevator 60 to lift a stack A off the belts 30, 31 and move them upwardly.

. Mounted on one stop 39 is electrical switch 64, which is normally open, so far as the elevator 60 is concerned,

and is closedupon engagement of the stack A. Closure of the switch 64 actuates a holding relay 65 (Fig. 13) and energizes a solenoid valve 60a, causing fluid to enter the bottom of the stacker cylinder 61, which is preferably pneumatic but may be hydraulic. The fluid then causes the piston 62 to move upwardly. The generally rectangular platform 63 is positioned between the belts 30 and 31 and in the area bounded by the frame members 45 and 47; so as the piston 62 rises, the stacking platform 63 engages the bottom of the stack A and lifts it up oif the belts 30 and 31 and above the stops 39, and pushes it through the normally horizontal gates 50, 51 which swing upwardly and outwardly to permit the stack A to pass through. If some stacks A were previously supported on the gates 50, 51 they, too, are carried up by the elevator 60 until the lower end 67 of the stack has passed beyond the inner edges of the gates 50, 51, at which time thereturn springs 54 close the gates 50, 51 downwardly and inwardly to their normal horizontal position.

Closure of the switch 64 also opensa circuit to the belt-driving motor 36, but the motor circuit closes as soon as the stack A rises above the switch 64. Since this takes only a few seconds, the slowing or stopping of the belts 30, 31 is hardly noticeable unless the stacker elevator 60 fails to lift the stack A above the switch 64. In that event, the switch 64 serves a safety function by preventing the jamming which would occur if the belts 30, 31 could then move additional cartons into the stacker D.

When the gates 50, 51 drop back to a horizontal position, one of them (e.g., 50 in Fig. 4) may actuate an electrical switch 68 which releases the holding relay 65 and thereby de-energizes the solenoid 66. Or the elevator 60 may actuate the switch 68 at the upper end of its stroke. As a result of this actuation, however achieved, the supply of fluid to the lower end of the stacking cylinder 61 is cut off, and its porting is reversed so that fluid enters the upper end of the cylinder 61 and lowers the elevator 60 to a level below the belts 30, 31. The gates 50, 511 intercept the stack A and support its lower end 67 as the elevator 60 moves down away from it. The cartons B, at this point, are held in alignment not only by the forward vertical gates 40, 41 and frames 45 but also by the frame members 47 and 48.

The elevator 60 is steadied by a pair of guide sleeves 70 that encircle vertical rod-like stationary guides 71. Each time the piston 62 rises, the guide sleeves 70 rise in relation to the stationary guide rods 71. Attached to one guide sleeve 70 is a bracket 72. When the bracket 72 rises, it releases the pressure on a spring 73, allowing it to extend. The lower end of the spring 73 rests on a stationary, frame-supported member 74, while the upper end of the spring 73 is secured to a reciprocating shaft 75 that extends down through an opening through the member 74. A dog 76 pivoted at 77 to the lower end of the shaft 75 rides up and down; on its upstroke its free pivoted attachment to the shaft 75 causes it to slide on by a tooth 78 of a ratchet wheel 79. However, when the piston 62 moves down and the spring 73 is compressed, the dog 76 moves down and engages the ratchet tooth 78 and moves it down, or forward, one step.

In this manner, each time the piston 62 returns to its lower position, the ratchet 79 is moved forward one step. One particular step, which (for example) may be the seventh step of a seven-toothed ratchet wheel 79, is provided with an extension member 80 adjacent it, and this extension member 80 is adapted to engage and close the contact of a normally open micro-switch 81, whose function will be explained in the next section. In other words, the switch 81 is closed only on the lowering of the piston 62 and platform 63 for the seventh time. Of course, the ratchet wheel 79 may have more or fewer teeth, and may be energized on a different step, if that is desirable.

The ratchet 79 thus acts as a counter and so may be replaced by another suitable type of cycle-counting device, but some form of counter is required for the operation about to be described. Each time the elevator 60 rises, another stack A is added to the bottom of a larger stack located above the horizontal gates 50, 51, and the large stack E is gradually built up. After a total of seven stacks A (in this example) have been accumulated into the one stack E, the next stage is to move the completed stack E out of the stacker D into the accumulator G.

Before passing to the next section, it should also be noted that each time the piston 62 is lowered the bracket 72 also closes a switch 82 which energizes the relay 43 and, through it, the solenoid 28, thereby pulling the stop gate 22 down so that another bundle A can pass on to the stacker D. However, on the seventh stroke down, the counter 79 indirectly (in a manner to be explained in the next section) opens a switch 83 that stops the motor 36.

'Then the belts.30, 31 stop, so that even though the stop gate 22 is open, no stack A will be moved into the stacker D during movement of the ejector F.

Also, it may be noted here that the normally horizontal stacker gate 51 on the side of the frame opposite the switch 68 is provided with an interlock switch 69 which prevents forward movement of the ejector F in case the gate 51 is not closed. On the previous six strokes, failure of the gate 51 to close would make little, if any, difference, because stacking would continue unaffected, but it would cause trouble if the ejector F were to attempt to move a tilted stack E into the accumulator G. If the switch 68 is arranged for actuation by the elevator 60, then there are two interlock switches 69, one for each gate 50, 51.

Advancing the stack E from the stacker D to the accumu- Iator G: The ejector F. (Figs. 1a, 3, 5 and 6) Closing the counter-actuated switch 81 actuates a holding relay 84, which in turn energizes a solenoid 85. A solenoid-controlled valve 8511 then sends fluid to the right hand port 86 (Fig. 1a) of a pneumatic cylinder 87 which is mounted rigidly to a stationary cross member 88 of the frame 35. The cylinder 87 is part of the ejector F, and entry of air into the port 86 causes a piston 89 to move horizontally from right to left, as shown in Figs. la and 5, (or from left to right as seen in Fig. 6). The piston 89 supports a vertically disposed ejector pusher block 90 on its outer end. The pusher 90 is of substantial vertical extent, and engages the entire height of the large stack E.

Therefore, as the cylinder 87 fills with air and the piston 89 and pusher 90 move forward, the stack E is forced forward with considerable pressure against the spring-mounted vertical gates 40, 41. The springs 46 yield to the pressure of the ejecting ram F, as trans mitted through the stack E, and the gates 41, 40 open outwardly (to the left in Fig. 5) permitting the stack E to be pushed through.

The ejector F is aided by two pairs of conveyor belts, lower belts 91 and upper belts 92, which at this time are freely moved by the stack E around their lower pairs of rollers 93 and 94 and upper rollers 95 and 96, respectively, enabling the ejector F to push against relatively low forces of friction. The upper belts 92 also restrain the upper end of the stack E and keep it from expanding due to internal pressures; e.g., in case some of the k.d.f. cartons B are warped. Chains 97 connecting the respective drive shafts of the belts 91 and 92 move them at the same speed; so the belts 91 and 92 also serve to convey the top of the stack E at the same speed as the bottom, as they move the stack E into the accumulator G. It will also be noted that the upper belts 92 actually extend over and overlie the stacker D and serve there to hold down the top of the stack E and aid from the beginning the movement of the stack E by the ejector F. Moreover, the height of the upper belts 92 is adjustable by threaded rods 98 and carriages 99 that support the rollers and shafts of the upper belts 92.

As Fig. 6 shows, a switch-operating cam 100 moves with the pusher 90, being attached to the end of a cam rod 101 that slides over a guide 102. When the cam 100 is in its extreme right hand position (as in Figs. 1a and 13) it holds the switch 83 closed; therefore, when it begins to move, the cam 100 opens the switch 83, and this opens the circuit to the motor 36, stopping the belts 30 and 31. This prevents jamming of the stacker D during operation of the ejector F. The belts 30, 31 remain stationary until the cam 100 returns to close the switch 83 at the end of the ejector stroke.

When the stack E passes beyond the gates 40, 41, the springs 46 close them. Shortly thereafter, the earn 100 engages and opens a normally closed switch 103, de-

energizing the relay 84 and the solenoid valve 85 and energizing (by a relay-controlled switch 341 through a switch 104 which was closed upon the opening of the the stacker D begins another cycle.

' Wheri the ejector F returns to its original (all the 'way to the right in Fig. 1a) position, the cam 100 opens the switch 104, de-energizing the solenoid 105. At the same time, the cam 100 closes the switch 83, starting the motor 36. The belts 30 and 31 then move again and carry a new small stack A- into the stacker D. Once again, a

'series of stacks A (for example, seven of them) are lifted sequentially by the stacking elevator 60 above the gates 50, 51 to form a second large stack E When that stack E has been completed and the seventh ratchet tooth has insertion of the lower cap or locking sheet H beneath the packs- E and E and the wings 111 and above the belts 91. Then, when the frame 110 and belts 91 are raised again, the belts 91 will support both the locking sheet H and the stacks E and E Although the wings 111 are then between the edges of the packs E and E and the lockingsheet H, thus does not interfere with the forward movement of the stacks E and E and the locking sheet H as a unit, since the wings 111 are only at the edges, and once the stacks have been moved forward out of the accumulator D the locking sheet H is fully united with them.

The horizontal wings 111 may be supported (at adjustable widths and lengths) from the top of the frame 35 been turned, energizing the switch 81 and the relay 84, 1

the ejector F again moves forward, pushing the stack E .in front of it, past thevertical gates 40, 41 and into contact with .the first single-pack E This time the action is somewhat diiferent. The second-pack E, is pushed against the first-pack E and engagesit and begins pushing it forward, the ejector F pushing both packs E and E along and between the belts 91 and 92. Soon after commencing to move, the stack E engages and closes a normally open switch 107, preferably located between the lower belts 91. The switch 107 bypasses the switch 103 that would normally stop the piston 89 at the position to which it pushed forward the stack E As a result, the piston 89 continues to move the stacks E and.E forward, unaffected by the switch 103, and moves them an additional distance until the earn 100 opens another normally closed switch 108 whose closure finally does dc-energize the relay 84 and return the ejector F to its original position, as before.

One purpose of this double stroking of the ejector F is so that the two single packs E and E will be in their correct position for the next operation. Yet it would waste energy to push the stack E the first time as far as the stack E finally gets pushed; so the short first stroke saves time and energy. Another purpose of the double stroking of the ejector D is to insure contact between the two stacks E and B In the first stroke, the stack E is pushed only far enough to allow the gates 40 and 41 ..to close.

into contact with the stack E before it reaches the' Then when the stack E is ejected it comes belts 91, the .end point of these belts being-positioned as shown for that purpose. If the first stack E were stroked further on its ejection so that the second stack E reached the belts 91 before touching the first stack E the belts 91 would begin moving, carrying the stack E with them and there would be a gap between the two stacks E and E It is very important that there be no such gap in the accumulator G, because that is where the lower locking sheet is applied that holds the'stacks E and E together. There would be no feasible way of curing such a gap, and the resultant bale would be faulty.

The locations of the electric contacts 107, 108 are adjustable for different sizes of cartons, and it may be men- The'acczlmulator G (FigsLIa and 6) The lower belts 91 are supported by rollers 93 and 94 that are journaled' in a movable frame 110 that can be lowered to retract the belts 91 downward, leaving the stacks E and E supported by their edges on a pair of parallel horizontal flanges, wings or support members by rods 112, while the belt-supporting frame may be supported by links 113 pivoted at one end 114 to the frame 110 and at the other end 115 to the frame 35, so that the frame 110 can be raised and lowered relative to the frame 35 by a cylinder 116 (pivotally secured to the frame 35) and piston 117 (pivotally secured to the frame 110). The link-s 113 give a parallelogram type of movement. The raising and lowering of the piston 117, frame 110, and belts 91 may be controlled by a solenoid valve 118a for the cylinder 116, the solenoid 118 being de-energized by a relay 119 on the opening of a normally closed switch 120. The switch 120 is opened automatically when thestack E reaches the forwardmost position to which it is pushed by the ejector F, for the stack E then. engages and rests upon the switch 120, causing the belts 91 to be lowered at once, until the frame 110 rests on the rests :121 and the single-packs E and E are suspended on the wings 111, so that the locking sheet H may then be inserted. The locking sheet H may not be, and usually is not, applied on some occasions, as will be explained later, and other devices may be used instead, if desired. When employed, the locking sheet H is'preferably approximately 4-6 wider on each side than the packs E and E for a purpose which will appear soon, and it is usually slipped in manually and centered by eye, through automatic insertion and centering are possible.

The belts 91 and 92 are free moving in the direction of flow, right to left, in Fig. 1a, due to the presence of a cam clutch arrangement 122, placed between a driving motor 123 and a drive gear 124-. The cam clutch 122 allows the belts 91, 92 to be pushed forward by freewheeling, without driving the motor 123; however, when the motor 123 is actuated, the cam clutch 122 locks and drives the belts 91 and 92 to move the stacks E and E from right to left, as in Fig. 1a. 7

If the press I is clear (as will be explained later) and after the lower locking sheet H is inplace (or if no locking sheet is to be used, whenever the operator so desires), a manual switch *125 may be closed (see Fig. 13). This switch 125, through the relay 119, energizes the solenoid 118 to pressurize the cylinder 116 and move the piston 117 and the frame 110 upwardly, placing the belts 91 in contact with the cap sheet H and lifting the stacks E and E off the Wings 111.

Then the operator can press a manual switch 126 that energizes a relay 127, which in turn actuates the motor 123. (The switches 125 and 126 may be actuated simultaneously by a single switch button.) A normally open interlock switch 128 keeps the relay 127 from actuating the motor 123 if the belts 91 are not in their lifted position, the switch 128 being closed when the frame 110 is in its raised position. Also the interlock switch 128 keeps the ejector F from acting even though it has received a signal from switch 81 unless the belts 91 are raised. The signal from the switch 81 is held in the machine until the belts 91 are again in the raised position. When the motor 123 is actuated, the clutch 122 is engaged to drive the belts 9-1 and 92, and the belts move the packs E and E with the locking sheet H from right to left as in Fig. 1a to the press I shown in 111. The purpose of lowering the belts 91 is to permit 1| Fig. 1b. While moving, the projecting edges 130 of the locking sheet H come in contact with curved metal rigid folding guides 131one of which is on each side of the main frame 35-and the edges 130 are folded from the horizontal to vertical position about the lower edges of the stacks E and E A final fold is made by a pair of vertical rollers 132, leaving the edges 130 as vertical flanges as shown in Figs. 1b and 8, as the boxes move into the press I between the guides 133 that serve to straighten and center the bundle in the press I.

When the stacks E and E move out of the accumulator G, the spring-urged switch 120 is restored to its normally closed position, holding the belts 91, 92 in their raised position until the switch 120 is again reopened.

The press I (Figs. 1b and 8-10) The switch 126 also closes a relay 140 which starts a motor 141 (Fig. 1b) that drives horizontal rollers 142 in the press I, through gears 143, 144 and 145 and chains 146 and 147; so they rotate and convey the single-packs E and E along in the press I. The packs E and E continue moving until the forward edge of the pack E reaches an adjustable vertical stop 150 and engages and opens a normally closed switch 151, thereby stopping both the motors 123 and 141. The rollers 142 are made, by gear ratio, etc., to move more slowly than the belts 91 and 92, so that a tight bundle is maintained, and the accumulator belts 91, 92 keep pushing the packs E and E together, rather than permitting them to separate a little in the press I. A single free or driven roller 152 may be provided between the end of the belts 91 and the first roller 142 to aid in conveying over the gap between.

It may be noted that the stop gate 150 preferably includes a telescopic frame that can be tall enough to contact the entire height of the stack E and yet will telescope inside itself when the press I closes, so that it will not be damaged upon closure of the press.

The press I has a strong main frame 155, into which the packs E and B are carried by the rollers 142, and the frame 155 is equipped with a press bed 156, including a series of strong steel horizontal beams 157 extending transversely across the frame 155. The rollers 142 are mounted on a separate frame 160 (see Fig. whose links 161 are pivoted to the frame 160 at 162 and are pivoted at 163 to the press frame 155, so that the rollers 142 may be raised above the bed 156 for driving the package or may be lowered below it during the pressing, haling and strapping. The raising and lowering is accomplished by a cylinder 164 whose piston 165 has its outer end 166 pivoted to a crank arm 167, which in turn is connected directly to one link 161 and indirectly by bars 16701 to the other link 161.

The frame 160 may be lifted by air, whose entry to the cylinder 164 is controlled by a solenoid valve 168a. The solenoid 168 may be dc-energized by a manual switch 169 to drop the rollers 142 by releasing air from the cylinder 164. The switch 169 may, if desired, be

tied into and be made a part of the stop switch 151.

The vertically extending stop gate 150 straightens the packs E and E by virtue of their forward inertia; so the stacks are very straight after they hit the gate 150.

The press 1 includes a heavy horizontal upper platen 170 which is mounted for vertical movement with respect to the frame 155 and bed 156 by means of four racks 171 on the vertical members 172 of the frame 155 and four pinions 173 on two axles 174, both axles being journaled in respective brackets 175 on the platen 170. The purpose of the racks 171 and pinions 173 is to obtain an equalized and truly vertical movement of the platen 170, so that it will not cock to one side or one end. The racks 171 assure that, at each end, the pinions 173 and their axle 174 will move together. Two center idler sprockets 176 are also provided on a shaft 177 midway between the ends on each side of the platen 179, and a chain 178, set in a figure-8, links drive gears 179 on the two axles 176. This arrangement moves the pinions 173 at each jendof the platen 170 at exactly the same rate and in the same direction. Thus, a perfectly uniform vertical movement of the platen 170 is assured at all times.

The vertical. movement of the platen 179 is powered preferably by a pair (or one or more) of hydraulic cylinders 130, 181 with pistons 182, 183; the cylinders 180, 181 being secured rigidly to the frame and the pistons 182, 183 being rigidly secured to the platen 170. A hydraulic pump 185 controls the supply of liquid to the cylinders 18% 181, its lever 186 being manually held in one direction (left in Fig. 8) to lower the platen 1 70 and in the other direction (right in Fig. 8) to raise the platen 176. Before lowering the platen 170 on a package requiring an upper locking or cap sheet K, the locking sheet K. is first inserted. The operator makes sure that the locking sheet K is properly positioned, if he wants a locking sheet K, and then moves the lever 186 to the left (Fig. 8). Since the press platen 170 should exert pressure on the carton package only when the cartons rest on the bed 156 and not when they are still on the rollers 142, the lever 186 is preferably arranged to throw the switch 169 automatically upon movement to the left of the lever 186. Thus, while the platen 170 is being lowered into contact with the stacks E and E the solenoid 168 causes air to bleed from the cylinder 164 and lowers the rollers 142. As a result, when the platen 170 compresses the stacks E and E the lower locking sheet H rests on the bed 156. The lever 186 may be arranged for automatic operation, or the operator may hold it to the left manually during all the time the platen 170 moves down, the platen stopping on his releasing the lever 186. A pressure gauge (not shown) may assist him in determining when to stop the platen 170, or, preferably, an adjustable pressure relief valve 187 is set to open at a desired pressure and stop downward movement of the platen, so that the stacks E and E will automatically receive enough pressure to insure a tight bale without damaging the cartons.

The bed 156 preferably has a pair of cross-members 190 set lower than the remaining bed members and provided with a pair of recessed channels 191, and crossmembers 192 of the platen 170 are set in recesses in the platen 179 and are likewise provided with recessed channels 1 93. In the recess or groove provided by the members 190 and 192, the bumper strips M may be inserted. Preferably, the operator places the lower bumper strips M in the channel-like area provided by the cross-member 190 before the frame is lowered and before moving the lever 186 to the left; the upper bumper strips M are preferably inserted in the groove provided by the member 192 as the press is closed or when it is partially closed. After the bumper strips M have been inserted and lie in their proper place, the baling straps I may be threaded through grooves 191 and 193 respectively, in the crossmernbers 190 and 192. The strap I may be kept readily available by being suspended on a spool 196 from a frame member 197, for free rotation. The strap I is passed around the package N and its ends joined together .by a machine 198 conventional for that operation and preferably suspended near at hand from a swiveled support 199. Where palletizing is to be used, a couple of pallet rails L, preferably with strap-receiving grooves 157, are inserted beneath the band I while it is being threaded around the package, preferably on the same side of the machine as the ripper P, which may be on the opposite side from the strapper 189. At this point, the single packs E and E have become an integrated, self-palletized unit N held together by cap sheets H and K.

The upper platen may now be raised by moving the lever 186 to the right (in Fig. 8) to reverse the pressure in the cylinders 118i) and 181. On reaching the top 200 which actuates a holding relay 201 that energizes a 174, one pass of the chain 178 engaging the center gear 75 solenoid 2 02. The valve 202a sends air into the right wo u handport 203 (Fig. 1b). of a stop gate cylinder 204 which is pivotally secured to the press frame 155, moving its piston 205 outwardly (to the left in Fig. 1b). The piston 205.is. connected by a pivotal connection 206 to a crank 207, which in turn is rigidly connected to a vertical pivot member. 210 of thevertical stop gate 150.. Movement of i the, piston 205 therefore rotates the stop gate 150 outwardly, on its hinge 211 until its main column 212 (connected .to the pivot member 210 by horizontal member 213) is entirely to one side of the press I, where it no longer presents an obstruction to the forward movement of the unitized package N.

A manual switch 215 (preferably manual, though it may be automatically actuated by the full opening of the gate 150) is then pressed. The switch 215 actuates the relay 140 for themotor 141,, but unlike the switch 126 doesnotactuate the relay 127 and the motor. 123. Whenthe motor141 is actuated, the rollers 142 start to revolve, and at the same time the solenoid-168 is energized, pressurizingthe cylinder 164 so that the frame 160.v is lifted. When the rollers 142 engage the lower cap sheet H, they pick up the package'N and convey it to a belt 216, whichis driven by the shaft 217 of one of the rollers 142 (and so by ,the motor 141). The belt 216 in turn conveys the package N to the conveyor 0, preferably but not necessarily of the gravity type.

The unloqder P (Figs. lb, 11 and 12) Y The conveyor has a frame 220 in which rollers 221 are mountedfor free rotation. The rollers 221 are set on an inclineyso: gravity causes the package N to slide down over them until it hits a generally vertical stop barrier 222,, where; it, engages and moves a switch 223. It will be noted that the barrier 222 also includes a frame 224 supporting rollers 225 for free rotation generally, on vertical, axes. -The tipping deviceP (see Figs. 1b, 11' and 12) is mounted adjacent the conveyor 0 and comprises a generally L-shaped frame 230 rotatably mounted on a shaft 231 which is journaled in brackets 232 on a portion 233 of the frame 220. The normally horizontal portion 234 of the tipper frame 230 has rearwardly mounted, freely rotatable rollers 235 and forwardly projecting fingers 236 which lie in between rollers 220 and carry small, freely rotatable rollers 237, which normally lie'below the upper surfaces of the rollers 221. The normally vertical portion 240 of the frame 230 also supports freely rotatable rollers 241 on horizontal axes.

When the switch 223 is moved by engagement of the package N, the relay 201 is de-energized, de-energizing the solenoid 202 and thereby closing the stop gate 150,

' so that a new set of stacks can be brought from the accumulator 0 into the press I by manually closing the switch 126. An interlock of circuits atthe switch 223 prevents this action heretofore.

Engagement of the switch 223 by the package N also actuates a holding relay 243 which, in turn, energizes a solenoid 244 whoseva-lve 244a sends fluid into a cylinder 245 (preferably hydraulic) at the left hand port 246 (Fig. 11 to pull its piston 247 in, to the right in Fig. 11.. The piston 247vis pivotally connected to a frame crank 248, sothis movement rotates the frame 230 counterclockwise in Fig. 11. Asrotation begins, the fingers 236 pick up the package. N and begin lifting it ed the rollers 221. After only a few degrees of tipping, the package Nbegins to slide along the rollers 237 and 235 and finally slides up against the rollers 241 of the vertical frame portion 2,40 In the meantime, and before the package N reaches the rollers 241, a cam 250 secured to the tipper frame portion 234 loses contact with a follower 251, which is supported by the frame 220, thereby opening a switch 252, de-actuating the relay 243 and de-energizing the solenoid 244. This sends fluid into the right hand port 253 of the cylinder 245 and the tipper frame 230 is then rotated (clockwise in Fig. 111) back to its normal position (solid lines in Fig. 11). The package N has been cleared oifthe rollers 221, so that other packages can follow, but the package N is still held horizontal by the tipper P, with the pallet rails L against the rollers 241.

It should now be stated that, while single-packs E and E are being united into the single self-palletized package N, new single packs E are being stacked in the stacker and moved into the accumulator G. However, to the next two packs the lower cap sheet H may or may not be added at the accumulator G, depending on the pack desired, and the upper cap sheet K may or may not be later added at the press I, depending on the pack. Also, no pallet strips L are applied then. However, each of these second series of single packs is baled, preferably, by a single strip 1', using bumper strips M to protect the edges, as before, to form a second group of two packages R (not shown) and S that are not unitized into a single package, because it is not necessary. They will soon rest on top of the unitized package N for movement therewith as a single unit, just as well as if they were completely unitized together.

The second series of baled (but unpalletized) packages R and S are then moved down onto the rollers 221, and, the forward package R moves into contact with the stopt 222, moving the switch 223. However, this time, some thing different happens, because the first package N, upon engagement with the vertical portion 240 of the tipper P, closed a bypass switch 255 which will operate; to hold the relay 243" closed (after its actuation by the;

switch 223), even when the switch 252 is open. Thercfore, the disengagement of the earn 250 from the roller: 251 will not cause the de-energization of the solenoid. 244.

As a result, the cylinder 245 continues to be filled with fluid and its piston 247 continues to be pulled in, even after the packages R and S have been lifted from the conveyor 0 and have slid against the palletized package N, until the frame 230 has tipped more than to the other dotted-line position in Fig. 11 (counterclockwise rotation-as in Fig. 11); in fact, until pressure is released from the switch 255, which happens only when the package'N and packages R and S roll off the tipping rollers 241. At this time, the packages N, R and S have been turned over 90 and have rolled to the position shown in lower broken lines in Fig. 11; and at this time the entire assembly of cartons rests on the pallets L. When they finally slide over the rollers 241, the pallets L are deposited on the ground or, better, on gravity rollers 256 on an inclined frame 257, along which they roll by gravity, to a desired loading point.

p the frame 230. Of course, the size of the tipper may be varied to hand-le the desired number of layers of any size of carton. The two-layer unit is a very good one for many uses, but one-layer, three-layer, four-layer, etc. units have been used very successfully. Two-layer units have also been alternated with three-layer units, and three-layer and four-layer units have been alternated. The basic device as described may be altered by means familiar to the man in the art to accomplish these results.

The electric circuit (Fig. 13)

Mo'st of the operating elements of the circuit'have already been discussed in preceding sections, but it re- There, a fork-hft truck may lift up each package assembly of; N, R and S and either stack them further, carry them mains to trace the preferred circuitry. Preferably, the power is supplied by a source 260 of 220-volt 3-phase current, which is connected to the motors 36, 123 and 141, and to a motor 261 that operates the hydraulic pump 185, by leads 262, 263 and 264. All the connections between these leads and the motors, however, are made through normally open relays 265, 266, 140 and 267, respectively, and these relays are actuated by a master-control circuit whose description will form the body of this section.

The circuit is provided with a master-control relay 270 which is energized upon closure of a master-control switch 271 and which obtains its power by tapping across leads 263 and264, via leads 273 and 274. Unless the master-control switch 271 is closed, the master-control relay 270 is open and nothing in the circuit will operate. All the remaining circuits are in series with the main relay 270. Most'of them are in parallel with each other across main power lines 275 and 276, but direct control over the motors 36, 123, 141 and 261 is maintained by leads 277 and 278 which are also in series with the master-control relay 270.

(A) The circuit controlling the stop gate 22.The relay 43-that controls the stop gate 22 may be in a circuit including a lead 280 connected between the main power line 276 and the gate-release switch 42. The gate-release switch 42 is connected by a lead 281, to a relay-controlled switch 282. In its normal, non-operative position, the switch 282 is connected by a lead 283 to the normally open switch 82. A manual starting switch 284 is also preferably connected to the lead 283 in parallel with the witch 82. The opposite sides of the normally open switches 82 and 284 are connected by a lead 285 to one side of the relay 43. A lead 286 joins the lead 285 to a normally open contact 287, which is closed by the switch 282 upon energization of the relay 43. A lead 288 joins the leads 285 and 286 to one side of the solenoid 28 which, when energized, pulls stop gate 22 down. A lead 289 from the opposite side of the solenoid 28, and a lead 290 from the opposite side of the relay 43, are connected together to a lead 291 which is connected through a lead 292 to the other power line 275.

Thus, when the switch 82 is in the position shown, which is the one normally assumed, no current can pass because the switch 282 is simply connected in series to a pair of open switches 82 and 284. Therefore, the relay 43 and the solenoid 28 are not normally energized.

It will be recalled that the seating of the elevator 60 at the lower end of its stroke closes the switch 82. Then, current will pass from the power line 276 through the lead 280, the switch 42, the lead 281, the switch 282, the lead 283, the switch 82 and the lead 285 into the relay 43 and out therefrom via the leads 290, 291 and 292 to the power line 275, energizing the relay 43. At the same time, current from the lead 285 passes via lead 288 to the solenoid 28 and from it, via lead 289, to the lead 291, so that the solenoid 28 is also energized directly upon closure of the switch 82. However, this is only its initial energization. The relay 43, being energized, moves the switch 282 away from the lead 283 to the contact 287. From then on, the switches 82 and 283 are out of the circuit, and current then passes from the power line 276 via lead 280, switch 42, lead 281, switch 282, contact 287 and leads 286 and 285 into the relay 43 to hold it energized and thereby keep the switch 282 against the contact 287. At the same time, of course, power passes from the contact 287 via leads 286 and 288 to the solenoid 28 and from it, through the leads 289, 291 and 292 to the power line 275. This is the normal operation of the stop gate circuit.

The solenoid 28 and relay 43 remain energized even though the switches 82 and 283 may have been opened in the meantime, until a stack of cartons opens the switch 42 mechanically, thereby opening the circuit. Opening the circuit tie-energizes the solenoid 28 so that the spring 16 27 pulls, up the stop gate 22, and it de-energizes the relay 43 so that the switch 282 moves to normal position, closed against the lead 283.

The purpose of' the manual switch 284 is to provide a way of actuating the circuit without having to rely upon the switch 82. Thus, suppose that the main switch 271 were opened, with the elevator 60 raised dlf the switch 82. When the main switch 271 was again closed, the stop gate relay 43 would remain de-energized, because both switches 82 and 284 would be opened. It might not be practical to restore the elevator 60 to its lower position, because to do so might mean throwing the counter 79 olf at least one count. Therefore, the switch 284 is closed to energize the stop gate relay 43 and the solenoid 28 in exactly the same manner as closure of the switch 82.

(B) The circuitry of the motor 36 and some related parts-A lead 293 from the power line 276 is connected by a lead 294 to the switch 83 and through it, to a lead 295 which is connected to. one side of the elevator lift switch 64'. When the switch 64 is in its normal position, shown in Fig. 13, it rests against a contact 296 which is connected by a lead 297 to a normally closed manual switch 298, provided for emergency use. The manual switch 298'is connected, via lead 299, to the relay 26'5 controlling the motor 36, the opposite side of the relay 296 being connected through the lead 300 to the power line 275.

Thus, with the switches 83, 64 and 298 closed, the motor 36 will drive the belts 30, 31, and opening of any of these switches stops the motor 36 and its belts. It will be recalled that entry of the stack A into the stacker D against the stops 39 does open the switch 64 during the initial raising of the elevato'r 60, and that movement of'the cam of the ejector F opens the switch 83.

(C) The elevator control circuit-When the stack A enters the stacker D and engages the stop 39, it throws the switch 64 away from contact 296 (thereby stopping the motor 36) and against a contact 301. The contact 301 is co'nnected by a lead 302 to a contact 303 normally closed by a relay-controlled switch arm 304. The normally open contact 305 of the relay-controlled switch 304 is connected by a lead 306 directly to the lead 295. The movable switch arm 304 is at all times connected by a lead 307 to the normally-closed elevatorreturn switch 68. A lead 308 connects the switch 68 to a lead 309, which goes to one side of the relay 65 and to a lead 310 which goes to one side of the solenoid 66, which operates the valve 66a that lifts the elevator 60. The other side of the solenoid 66 is connected by a lead 311 to the leads 291, 292, and the other side of the relay 65 is connected by a line ,313 to the lead 291, which is connected through the lead 292 to the main power line 275.

Thus, when the switch 64 is thrown against the contact 301, current passes from power line 276 through leads 293 and 294, switch 83, lead 295, switch 64, contact 301, lead302, contact 303, switch 304, lead 307, switch 68, leads 308 and 309, to the relay 65 and from there through leads 313, 291 and 292 to the power line 275, energizing the relay 65. Simultaneously, the solenoid 66 is-energized by the parallel circuit through leads 310 and 311. The holding relay 65 immediately takes over and closes the relay switch 304 against the contact 305, so that the power thence comes directly from the line 295 through lead 306 and switch 304 to the switch 68 and therethrough to retain the relay 65 and solenoid 66 energized. Then, when the switch 64 returns to its normal contact 296 and opens the contact 301, by virtue of the elevator 60 having raised the stack A above the switch 64, the elevator 60 continues to rise. The elevator 60 is stopped when the switch 68 is opened either by the elevator reaching a. desired height or by the return of the 'gates 50 and 51. When this happens, the relay 65 and solenoid 66 are de-energized, and the switch 304 side opposite the lead 321.

'17 returns'to the contact 303 which is, of course; then an open circuit. The porting of the solenoids valve 66a 'is reversed; so the elevator 60 drops to its lowered position and, as stated earlier, energizes the switch 82 at that lower position.

. (D) The ejector circuit-The lead 292, which is connected between the power line 276 and the lead 291, is also connected to a lead 320-r the lead 320 may be connected directly to the line 276, if desired. One branch, 321, from the lead 320, passes to one side of the ejector operating relay 84, which is normally open. The other branch lead 322 is connected by a lead 323 to the main ejector solenoid 85 and by a lead 324 to the return-air solenoid 105 for returning the ejector F. The circuit to the return-air solenoid 105 is normally open because the other side of the solenoid 105 is connected by a lead 325, to one side of the normally open switch 104,

which does not'close until the cam 100 is moved by movement of the ejector piston 89.

The other side of ejector solenoid 85 is connected by a lead 326 to a normally closed interlock-switch 327 located in the accumulator G and adapted to be opened whenever the belts 91 are lowered, so that the ejector F cannot push the stack E into the accumulator G if the belts 91 are not in their raised position. The other side of the switch 327 is connected by a lead 328 to the normally closed switch 69 which is actuated by the gate 51 to prevent motion of the ejector F in case both gates 50 and 51 are not'closed.

'The opposite side of the switch 69 is connected by a lead 330 through a normally closed switch 331 in the accumulator motor relay 266 to a lead 332. When the 103, a lead 337, the normally closed second-stroke ejector-return switch 108, a lead 340 and the relay 84, on the In parallel with the switch 103 and across leads 336 and 337 is the normally open second-stroke by-pass switch 107. A normally open relay-controlled switch 341 is also normally closed against contact 342, which is connected by lead 343 to the normally open switch 104. The other side of the switch 341 is connected to both the switch 81, by a lead 344, and to the leads 293 and 294 by a lead 345.

'Upon closure of the switch 81, current passes from the power line 275, by leads 292, 291, 320, and 321, to the relay *84, and from there via lead 340, switch 108, lead 337, switch 103, leads 336 and 335, switch 81, and leads 344, 345 and 293 to the other power line 276. The current, therefore, energizes the relay 84, moving the switch arm 34-1 away from the contact 342 and against the contact 334. Now current flows from power line 275 through leads 292, 291, 320 and 321 to the relay 84 and thence through lead 340, switch 108, lead 337, switch 103, leads 336, 335, and 333, contact 334, switch 341, and leads 345 and 293 to the power line 276. The relay 84 is thus held energized, and it continues to hold the switch 341 against the contact 334.

With the relay 84 energized, the current passes from the line 275, via leads 292, 291, 320, 322 and 323, through the pusher solenoid 85, lead- 326, switch 327, lead 328, switch 69, lead'330, switch 331, leads 332 and 333, contact 334, switch 341 and leads 345 and 293 to the power line 276. 'IihereforeQthe solenoid 85 is energized and its valve 85a causes the ejector F to move.

Movement of the ejector -F immediately moves the cam 100 and opens the switch 83, stopping the motor '36. simultaneously, the movement of the cam 100 causes the switch 104 to close, but nothing happens from this just yet, because the switch 104 is connected to the open contact 342.

As the cam is moved by the ejector F in its first stroke, it opens the switch 103. This, of course, opens the circuit and de-energizes the relay 84, returning the switch 341 to its normal position against the contact 342. Therefore, the solenoid 85 is de-cnergized and the ejectorF is stopped. 'But, the switch 104 is now closed; so current flows from the power line 275, via leads 292, 291, 320, 322 and 324, to the return-air solenoid 105 and from there through lead 325, switch 104, lead 343, contact 342, switch 341 and leads 345 and 293 to the power line 276, thereby energizing the solenoid 105, whose valve 105a causes the ejector F to be pushed back to its normal position. The solenoid 105 is de-energized when the cam 100 breaks the switch 104 and simultaneously closes the switch 83, starting the motor 36.

With one package'E already in the accumulator G, the operation of the second stroke of the ejector F differs only in that the cam 100 continues to move past the opened switch 103, because the first package E -shortly after beginning its movementclosed the bypass switch 107, causing the current to by-pass the switch 103 through the switch 107. The ejector F therefore continues to move until the cam 100 opens the switch 108, upon which the return circuit is again brought into play, exactly the same way as before; 1

(E) Circuit for lifting and lowering the belts 91. Fig. 13 shows the solenoid 118, relay 1'19 and switch so actuated that the belts 91 are in; their lower position. At this point, the solenoid 11 8 is connected to the power line 275 via'leads 350 and 351, and on its opposite side is connected to a lead 352, one branch 353 of which leads through the normally closed switch 120 and lead 354 to one side of the relay 119.- However, the other side of the relay 119 is simply through a lead 355 back to lead 350, so there is no circuit then and the relay 119 is not energized by that circuit. Another branch 356 from lead 352 goes to the relay-controlled switch 357 which, at this time, rests against contact 358, which by lead 360 is connected through a closed portion 361 of the switch and a lead 362 to a lead 363. The lead 363, in one direction, goes down to the normally open relay 127 and, in its other direction, to the normallyopen interlock-switch 128.

The connection to the power line 276 is through a lead 364, one branch 365 of which passes to the normally open contact 366 of the switch 357. The other branch 367. passes to the open portion 368 'of the switch 125. The other side of the switch portion 368 is connected by a lead 369 to the switch 357.

The switch 125 is manually operated, and until it is 'closed the belts 91 remai-n in their lower position, as

they are when the current is 011:, due to the fact that the air cylinder 116 is bled when the solenoid 118 is not energized.

Operation, therefore, begins by moving the switch 125 manually to the position where its switch arm 368 closes across leads 367 and 369. At the same time, it will be noted that the switch 361 is opened. Current from the power line 276 flows via leads 364 and 367, switch portion 368, lead 369, and lead 352, to the solenoid 118, from which, by leads 351 and 350 it flows to the other side of the line 275. Therefore, the solenoid 118 is immediately energized, and its valve 118a starts raising the belts 91. At the same time, the parallel circuit from lead 356 passes via lead 353, switch 120, and lead 354, to the relay .119 and from the other side of the relay through leads 355 and 350 to'the power line. 275, energizing the relay 119. This moves the switch 357 away from the contact 358 and against the contact 366. This, in turn, means that now current flows directly to the solenoid from the line- 276 via leads 364 and 365, switch 357, leads 356 and 352 and, through the solenoid 118, through the leads 351 and 350, to theline 275. This a "19 current continues to energize 'the solenoid 118 after release of the switch .125, which returns to its normal position. Current ,also flows via the switch 120, directly through the relay 119, and holds it energized. This means that the belts 91 stay up until switch 120 is opened, either manually (if that should be desired) or, in normal operation, by arrival of the stack E at the end of the accumulator G, depressing the switch 120. When the switch 120 is opened, the solenoid 118 and relay 119 are de-energized, the switch 357 moving back against the contact 358. The de-energization of switch 119 and solenoid 118, of course, causes the belts 91 to be lowered for insertion of the cap sheet. After the cap sheet has been inserted and it is desired to start operations again, the belts 91 are raised by manually pressing the switch 125 and holding it momentarily until the relay 1 19 takes over.

(F) Circuit for moving the stacks E and E from the accumulator G to the press I.The motor 123 which drives the belts 91- and 92 is energized by the relay 266, one side of which is connected to the power line 275 through a lead 370. The other side is connected via lead 371 to the switch 128. The switch 128 is open whenthe belt 91 is lowered and is .closed when the belt 91.is raised, by mechanical engagement of the belt frame 110. The switch 128 is connected to a normally open contact.372 adjacent the relay 127 by the lead 363. Moreover, since the switdh 128 is open as long as the belt 91 is .down, actuation of the relay 191 has no effect on the motor 123.

The relay 127, when energized, closes two normally open switches; closing switch 373 against the contact 372 and the switch 274 against a contact 375. The switches 373 and 374 are always connected together by lead 376 and are connected through lead 377 to one side of the relay 127. They are also connected via lead 378 to a contact at a normally open switch portion 380 of the switch 126. The normally open contact 375 of the switch 374 is connected via lead 381 to a pole 382 on the opposite side of the normally open component 380 of the manual switch 126 and to a pole 383 of another normally open component 384 of the switch 126. The lead 381 is also connected through pole 385 to the normally closed manual stop switch 386, which can be used to stop the motion of the motor 123 at any time, as will be seen hereafter.

Opposite the pole 383 of the normally open switch component 384 is a lead 387, which is connected to a normally open switch 388 that is closed only upon energization of the relay 140 that drives the motor 141. The other side of the switch 388 is connected by lead 389 to the lead 381.

The opposite side of the relay 127 is connected by leads 390 and 391 to the power line 275. The other side of the switch 386 is connected by a lead 392 to the normally closed switch 151 at the stop gate 150. The other side of the switch 151 is connected by lead 393 to the switch 223, at the unloader. Leads 394 and 395 connect the opposite side of the switch 223 to the power line 276.

It will be obvious from the drawing that the circuit, as shown, is openbecause switches 126, 373, 374, and 388 are all open. For operation of the circuit, therefore, the manual switch 126 is closed for a moment and, in that case, the switch component 380 bridges between lead 378 and pole 382, while switch 384 bridges between pole 383 and lead 387. The current can flow from line 276 via leads 395 and 394, switch 223, lead 393, switch 151, lead 392, switch 386, pole 385, lead 381, pole 382, switch 380, leads 378, 376 and 377, relay 127 and leads 390 and 391 to the power line 275. As a result, the relay 127 is energized and switches 373 and 374 are closed. Current can then flow from the power line 276 via leads 395 and 394, switch 223, lead 393, switch 151,'lead 392, switch 386, pole 385, lead 381, contact 375, switch .374,

lead 376, switch 373, contact 372, lead 363, switch 128 (if the belt is up), lead 371, relay 266 and lead 370 to the line 275. The-resultant energization of the relay 266 starts the motor 123 .and drives the belts 91 and 92. Similarly, the current from the line 276, flowing as before to the lead 376 also flows through lead 377, relay 127, and leads 390 and 391 to the line 275, keeping the relay 127 energized after the switch 126 is released.

When the switch 126 is first closed, current from the power line 276 via the leads 395, 394, 393 and 392 as before described passes across switch 386 to pole 385 and pole 333 and from them through switch 384 to lead 387. From there it goes by a lead '400 through a normally closed switch 401 and lead 402, the relay and a lead 403, to the power line 275. Thus the relay 140 is energized, starting the motor 141 which drives the rollers 142 in the press -I. Also, energization of the relay 140 closes the switch 388; so when the switch 126 is released, current from line 276 to lead 381 flows via lead 389, switch 388, and lead 387 to the lead 400 and thus through the relay 140 as before, holding the relay 140 energized and the switch 388 closed. So the motors 141 and 123 continue to run till the stack E mechanically opens the switch 151, which opens the circuit and de-energizes the relays 127,266 and 140.

'Both motors 141 and 123 can, of course, also be stopped by manually opening the switch 386, and opening the switch 401 will stop the motor 141.

(G) Raising and lowering the rollers ]42.-The circuit for the solenoid 168 and switch 169 will next be described. The solenoid 168 is connected to the lead 391 by a lead 408 and by a lead 409 to one side of a relay 410, and from there by a lead 411, a normally closed, relay-opened contact 412, and a lead 413 to the lead 387. The other side of the relay 410 is connected by a lead 414 to the leads 391 and 390. The switch 169, normally closed, is connected to the power line 276 by a lead 415 and by a lead 416 to the normally open contact 417 of a switch 418 operated by the relay 410.

The relay 410 may be energized by the manual switch 126, which as described before, energizes the relay 140, closing the switch 388. In this instance, the circuit from power line 276 is through leads 395 and 394, switch 223, lead 393, switch 151, lead 392, switch 386, pole 385, leads 381 and 389, switch 388, lead 387, lead 413, switch 412 and lead 411, and through the relay 410 and leads 414 and 391 to the power line 275. The relay 410 is then energized and closes the normally open switch 418 against the contact 417. Therefore, until the switch 151 opens, the relay 410 continues to hold by the circuit from line 275 through leads 391 and 414, the relay 410, switch 418, contact 417, lead 416, switch 169, and lead 415 to the other power line 27 6.

When the switch 169 is opened, the relay 410 will be de-energized, the switch 418 moving away from the contact to its opposite position, which is then an open circuit.

The power circuit holding the solenoid 168 energized during energization of the relay 410 is from power line 275 through leads 391 and 408, solenoid 168, switch 418, contact 417, lead 416, switch 169, and lead 415 to the power line 276. When the solenoid 168 is energized, its valve 168a raises the rollers 142 and keeps them up. Again, opening the switch 169 de-energizes the solenoid 168 and lowers the rollers 142. Closing the switch 169 is inelfective until the switch 388 is again closed by the relay 140. 1

(H) The circuit for opening and closing the stop gate 150.One side of the switch 200 is connected by lead 420 to lead 393. The other side is connected by lead 421, to one side of the relay 201 and by lead 422 to one side of the solenoid 202. Lead 423 from the other side of the relay 201 and lead 424 from the other side of the solenoid 202 are connected by lead 425 to the power line 275. .A normally open relay-controlled switch 426 21 is contrasted to the lead 421, being normally'held away from a contact 427 which, in turn, is connected by a lead 428 to the lead 393.

When the switch 200 is closed, power from line 276 passes through leads 395 and 394, switch 223, lead 393, lead 420, switch 200, lead 421, relay 201, and leads 423 and 425 to the power line 275, energizingthe relay 201. At the same time, the solenoid 202 is energized by the parallel circuit leads 422 and 424. Upon energization, the relay 201 closes the switch 426 against the contact and from then on, so long as the relay 201 remains energized, power passes directly from lead 276 through leads 395 and 394, switch 223, leads 393 and 428, switch 426, relay 201, and leads 423 and 425 to power line 275. The solenoid 202 is retained energized by the parallel circuit from the switch 426, through leads 421 and 422, the solenoid 202 and lead 424 to the lead 425. The solenoids valve 202:: operates the cylinder 204 that opens the gate 150 and holds it open until the switch 223 is opened by the package N. When the switch 223 is opened, the relay 201 and solenoid 202 are de-energized, and since the switch 200 is of the type that remains closed only instantaneously, the relay 201 will not be re-energized when the switch 223 again closes.

(I) The hydraulic pump motor 261.-The hydraulic :pump motor 261 is energized, at all times when the mastter control switch 271 is closed, by current through lead .430, from line 275, and through the relay 267 and lead #431 to the other power line 276. With the motor 261 energized, fluid can be pumped at any time by the manual tcontrol therefor.

(J) The circuit for moving the baled package N from [the press I to the tip-over unit P.-It is not desirable 2. to have to run the motor 141 only when the motor 123 iis running. Therefore, a difierent control switch 215, ;a normally open manually controlled switch, is used to :move the package N from the press I to the unloader P. .The manual control switch 215 is preferably supplied vwith two switch elements 440 and 441. Element 440 {bridges leads 442 and 443, while the element 441 bridges the leads 444 and 445. The leads 443 and 445 are both connected to the lead 387. The lead 442 is connected to the lead 389, and the lead 444 is connected to the lead ;?393.

Closure of the switch 215 causes the two switches 440 :and 441 to bridge their respective leads. The motor 141 :then operates through the circuit from the line 275, lead 403, the motor relay 140, lead 402, switch 401, leads 400, 387 and 445, switch element 441, leads 444 and 393, switch 223, and leads 394 and 395, to the power line 276. Thus, the relay 140 is energized and the motor 141 will run. Once the relay 140 is energized, the switch 38 8,is clbsed; therefore, upon release of the switch 215, the motor 141 will run by the circuit from line 275 through lead 403, relay 140, lead 402, switch 401, leads 400 and 387, switch 388, leads 389 and 381, pole 385, switch 386, lead 392, switch 151, lead 393, switch 223, and leads 394 and 395 to the power line 276. Thus, the motor .141 remains running until the circuit is broken by the :package N opening the switch 223, which stops the motor 141 and de-energizes the relay 140, breaking the switch 388.

The upper switch portion 440 is used to insure that the rollers 142 will be in their raised position. This happens because the strapping section switch 169 is closed. Therefore, current passes from the line 276 through leads 395 and 394, switch 223, leads 393 and 444, switch 441, leads 445, 387 and 443, switch 440, leads 442 and 389, switch 388, leads 387 and 413, switch 412, lead 411, rela y 410 and leads 414 and 391 to the line 275, thereby energizing the relay 410. This causes energization of the solenoid 168 through the circuit of line 275, leads 391 and 408, solenoid 168, lead 409, switch 418, contact 417, lead 416, switch 169, and lead 415 to the line 276. The'relay 410 is retained energized after the switch 215 is opened bythe circuit parallel to the solenoid 168, as described before.

(K) The tip-over circuit.The tip-over circuit is inoperative so long as the switch 223 is in its normal position, as shown in Fig. 13; but this switch 223 is moved when the package N engages it against a contact 450. The contact 450 is connected through lead 451 to a normally open contact 452 which is closed by a switch 453 upon energization of the relay 243. Similarly, the lead 395 is, itself, connected by a line 454 to the normally open switch 453, and to another normally open switch 455, both operated by the relay 243. The normally open contact 456 for the switch 455 is connected by a lead 467 to the solenoid 244 which, in turn, is connected by a lead 458 and lead 425 to the power line 275.

The contact 450 is also connected by lead 460 to one side of the normally closed switch 252 and by lead 461 to one side of the normally open by-pass switch 255. A lead 463 from the opposite side of the normally closed switch 252 and a lead 464 from the other side of the switch 255 are connected by a lead 465 to one side of the relay 243. The other side of the relay 243 is connected by the lead 466 to the lead 425 and thence to the line 275.

Thus, when the switch 223 is moved against contact 450, current passes from line 276 through leads 395 and 394, switch 223, contact 450, lead 460, switch 252, leads 463 and 465, relay 243, and leads 466 and 425 to power line 275, energizing the relay 243. This causes the switches 453 and 455 to close, sending current from line 276 through leads 395 and 454, switch 453, contact 452, leads 451 and 460, switch 252, leads 463 and 465, the relay 243, and leads 466 and 425 to the line 275, thereby holding the relay 243 closed upon release of the switch 223. At the same time, power from line 276 through leads .395 and 454, passes through the switch 455, contact 456, lead 467, solenoid 244, and leads 458 and 425 to the power line 275, actuating the tipping cylinder 245 through the valve 244a. Tipping continues until, on the first package N, switch 252 is opened by the cam 250 as described heretofore. gizes the relay 243, therefore, shuts off the solenoid 244, and valve 244a reverses its ports.

As the second tipping begins, the switch 255 is already closed by the package N, but since that occurred after the relay 243 was de-energized and, since the switch 223 was then also back in its normal position, there was no re-energization when the switch 255 closed. When the switch 223 again opens, the relay 243 is energized in the same manner as before, but it is kept energized after the switch 252 is opened by current passing through the switch 255, which remains closed until the bundle leaves the tipping unit itself, which releases the switch 255 and deenergizes the relay 243 and the solenoid 244; the valve 244a then reverses its ports, and the tipping frame 230 returns to normal position.

Operation The operator starts the device by closing the master control switch 271 which energizes the master-control relay 270. With the device in its normal position, this will cause the belt-drive motor 36 to operate, moving the belts 30, 31. Small stacks A of boxes B enter the machine from the conveyor C, one at a time. As the first stack A enters and comes onto the belts 30, 31, it is pulled away from the stacks A behind it by the greater speed provided by the driving belts 30 and 31 as compared with the gravity feed of the rollers 21. This causes the first stack A to have a gap between it and the second stack, so that when the stack A opens the switch 42, the solenoid 28 is de-energized. The weight of the boxes in the first stack A is suflicient to hold the gate 22 down until it has passed beyond it, but

upon its having passed, the gate 22 is immediately Opening. the switch 252 de-ener- 23 pens only after the stack elevator 60 has lifted the first stack A above the gates 50, 51 and has returned to its bottom position.

The first stack A, moving along the belts 30, 31, passes between the straightening guides 38 into the stacker frame and comes against the stop 39, moving the switch 64 from contact 296 to contact 301. This stops the motor 36 until the boxes B are lifted above the switch 64, and it energizes the relay 65 so that the solenoid valve 66a sends air into the pneumatic cylinder 61 to raise the elevator 60 with the stack A on top of it. As the raising continues, the stack A pushes open and upward the gates 50, 51. After the stack A passes above the top of the gates 50, 51, the springs 54 close the gates 50, 51 below the stack A, and closing of the gateStl (or attainment by the elevator 60 of a predetermined height) opens the switch 68, de-energizing the relay 65 and the solenoid 66, so that the valve 66a sends air into the opposite end of the cylinder 61 and lowers the elevator 60. As the elevator 60 goes down it leaves the first stack A on top of the gates 50 and 51.

When the elevator 60 returns, it energizes the switch 82 opening the gate 22 and sending the second stack A into the stacker D. The switch 64 is again energized, and the elevator 60 carries the second stack A above the gates 50, 51 and adds it beneath the first stack A. The elevator 61 again drops, and continues in this manner to lift stacks A above the gates 50, 51 until the required number necessary to make the stack E has been reached. By way of example we have given the number of seven stacks A to be incorporated into the stack E; and so a seven-toothed ratchet wheel 79' is provided.

The return of the elevator 60 in each instance causes the .dog 76 to move against a ratchet tooth 78 and move the ratchet wheel 79 around one tooth. At the seventh tooth, the projection 80 closes the micro-switch 81, energizing the relay 84. This energizes the solenoid 85, and its valve 85a sends the ejector F forward. The pusher block 90 at the forward end of the piston 89 moves the stack E forward, forcing open the gates 40, 41 against the pressure of the torque springs 46. After the pusher 90 has pushed the stack E forward, beyond the gates 40, 4-1, the springs 46 close the gates 40, 41 and, shortly thereafter, the switch 103 is opened by the cam 100 on the cam rod 101. This tie-energizes the relay 84 and tie-energizes the solenoid 85. It also energizes the return air solenoid'105, and its valve 105a sends air into the opposite end of the cylinder 87 at the port 106 and retracts the pusher block 90.

When the ram 90 began its pushing action, the interlock switch 83 opened; so the motor 36 stopped and it became impossible during operation of the ejector F to deliver any more stacks A into the stacker D. Upon the return of the ejector F, the switch 83 is closed by the cam 100 so that the motor 36 again begins running, and a new series of stacks A is taken into the stacker D and formed into the stack E, as before.

The second stack E having been formed, it is pushed, as before, by the ejector F on actuation by the seventh ratchet tooth. As before, the belts 91, 92 aid the ejector F in this pushing. After the ejector F and second package E begin pushing the first package E the package E engages and closes the switch 107 which by-passes the switch 103, so that when the cam 100 opens the switch 103 nothing happens, and the pusher 90 continues to move until the second-stop switch 108 is opened by the cam 160. Then, as before, the relay 84 and solenoid 85 are de-energized and the solenoid 105 is energized, retracting the ejector F. Also as before, the motor 36 is stopped during movement of the ejector F and, as before, the motor 36 begins to run again as soon as the cam 100 engages the switch 83 and closes it.

At the end of its stroke, the forward bundle E in the accumulator G opens the switch 120, which de-ener- 'gizes the relay 119 and the solenoid 118, bleeding air from the cylinder 116 and lowering the frame that carries the belts 91. The stacks E and E are thereby lowered to rest on the wings 111. A cap sheet H is inserted between the belts 91 and wings 111, if desired at this time, depending upon whether this is the first group of two packs E and E or the second group of two packs to go through the accumulator G. After the cap sheet H has been put in manually and, if other things ahead are clear, the operator presses the manual switch 126 which energizes the relays 127 and and starts both motors 123 and 141 going.

The motor 123 causes the belts 91, 92 to move the stacks E and E to the press I, while the motor 141 causes the rollers 14-2. in the press I to take over and move the packages E and E in the press I at a slower rate than the belts 91, 92 until the packages reach the stop-gate and open the switch 151, which stops both motors 123 and 141. During the movement from the accumulator G to the press I, the folders 131 force in the projecting edges 130 of the cap sheet H, and the rollers 132 press the edge portions 130 straight against the side of the package. The fact that the belts 91, 92 move faster than the rollers 142 helps keep the packages E and E pushed together. In fact, when they engage the stop gate 151 they still have sufficient momentum to cause them to straighten up, in case they are not vertical.

There are usually two operators at the press I, one on each side. One of them is the same one who puts in the cap sheet H at the accumulator G, and he now puts in the upper cap sheet K. The other operator usually helps put the lower bumper strips N into the grooves provided by the members 190 and then, if the stacks E and E are in order, he pushes the lever 186 to the left (as seen in Fig. 8), causing the hydraulic pump 185 to pump fluid into the cylinders 180 and 181 and, thereby, cause the platen 170 to begin descending. However, closure of the lever 186 to the left also opens the switch 169, which de-energizes the relay 410 and solenoid 168; so the cylinder 164 retracts its piston and lowers the frame 160 and its rollers 142 below the level of the bed 156 before the platen engages the upper cap sheet K or the top of the box stack. The platen 1713 continues to descend and the operator holds thte lever 136 to the left until the desired compression has been achieved, which he may notice on a gauge (not shown) or which may be automatically determined by the relief valve 187.

When the press I has been lowered part way, it is usually stopped for insertion of the upper bumper strip into the groove provided at 192. With both bumper strips M in position, the stack is compressed fully by the platen 170. Then the straps J from the reel 196 are passed around the stacksusually through the upper channels 193 over the bumper strips Mdown along the opposite ,side (over the pallet boards L, which are now inserted if used) and under the lower bumpers M through the bottom channels 191, and then up the right-hand side, as shown in Fig. 8, to the actual strapping device 198 where the ends are brought together in the strapping machine. The operator then energizes the strapping machine 198, which usually has its own motor as made by the manufacturer, and it tightens the band I very tightly around the package. Usually two strapping machines 198 are used and both kept in position from their swivel support 199, in approximately the position where they will be used. For the same reason, there are usually two reels 196, both suspended from a frame member 197 at a location approximately above that where they will be used. Because of their tendency to obscure the machine, they were not shown in Fig. 1b. Meanwhile, the other operator is inserting the lower cap sheet H beneath another stack in the accumulator G.

.When thebaling has been completed, which takes only 25 about 40 seconds, the operator moves-the lever 186 to the right and the hydraulic pump bleeds fluid from one side of the cylinders 180, i181 and sends it into the other side, lifting the platen 170. The platen 170, in both directions, is guided by the rack-and-pinion structure with the racks 171 and pinions 173 cooperating with the axles 174 on the pinions on each end, and with the chain 178 joining the axles 174 at the two ends so that the platen 170 always moves perfectly vertically. This is much more important, of course, on the down stroke Where it is necessary for the package to end up flat.

When the platen 170 lifts, it engages the switch 200, energizing the cylinder 204 which opens the stop gate 150. The operator then presses the manual switch 215 to energize the motor 141 and start the bundle N moving out of the press I. The self-palletized package N moves on to the conveyor and moves by gravity along over the rollers 221 until it engages the stop 222, automatically throwing the switch 223. The switch 223 then energizes the relay 243, which energizes the solenoid 244 to begin tipping the unloader P. The unloader P lifts the package N off the rollers 220 onto its finger rollers 237, on which it begins to roll, and it rolls down the incline provided by the tipped unloader P, onto the rollers 235 and along them until it engages the rollers 24 1 supported by the vertical portions of the frame 230. At that time, the package N closes the switch 255, but it is by then too late to do anything, because by thenthe cam 250 has left its roller 251 and opened the switch 252, which de-energizes the relay 243 and solenoid 244 and causes the unloader P to return to its horizontal position.

A second series of two bundles R and S, handled in the same way in the stacker, have meantime been passed into the accumulator G, where no cap sheet was applied and, from there, into the press I where, again, no cap sheet was applied nor was any pallet board applied. However, bumpers M were inserted as before, and a single strap I was passed around each bundle, with the bumpers M protecting the corners of the bundles R and S. Bundles R and S are then moved forward as before, into the tipping device P, and against the switch 223.

Engagement of the switch 223 again causes the unloader P to begin tipping; but, this time, due to closure of the switch 255 by the bundle N, the tipper not only will lift the packages R and S olf the rollers 221 and roll them down against the package N, but will continue to tip until it is past more than 90, and the pallets L are able to slide along over the rollers 241 and drop down to the conveyor Q wherethey slide over the gravity rollers 256 to the desired loading point. Thus, the package ends up by having a baled, unitized package N with cap sheets H and K and pallet boards L at the lower level, with the pallet boards L resting on the floor, and with two baled unpalletized packages R and S resting side-by-side on top of the self-palletized package N. Of course, as mentioned before, the unit may comprise more or fewer layers.

To those skilled in the art to which this invention re-' la-tes, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the invention. The disclosures and the description herein are purely illustrative and are not intended to be in any sense limiting.

What is claimed is:

1. A device for making a self-palletized bale of k.d.f. corrugated paper cartons, comprising: means for forming at least one stack of k.d.f. cartons over, a bottom oversize locking sheet; means for folding the portions of said locking sheet that extend beyond said stack against the sides of the stack; means for compressing the stack; means for positioning overlength reinforcing and protective members on predetermined portions of said comre s d' t sk Q Portions o hbv a b l s t d against one side of the stack; means for locating metal straps around said compressed stack, with each said strap overlying a said board and overlying some of said reinforcing and protective members; means for securing the ends of said strap together tightly to form a bale; means for relieving the pressure of said compressing means against, said stack after the bale is formed; and means for turning said bale 90 to rest it on said boards, which are then used as pallet boards.

2. A device for making a self-palletized bale of k.d.f. corrugated paper cartons, comprising: means for forming a stack of k.d.f. cartons over a bottom oversize corrugated paper cap sheet; means for folding the portions of said cap sheet that extend beyond said stack against said stack; means for placing said stack under pressure; means for positioning overlength corrugated paper reinforcing and protective members against predetermined portions of said stack while it is under partial pressure, upon portions of which rabbeted boards are placed, rabbet outward, at one end of the stack; means for passing metal straps around said stack while it is under pressure, each said strap lying in the rabbet of a said board; means for securing the ends of said strap together tightly to form a bale while said stack is under pressure; means for releasing the pressure on said bale; and means for turning said bale 90 to rest it on said boards, which are then used as pallet boards.

3. A device for making a self-palletized bale of k.d.f. corrugated paper cartons, comprising: means for forming a stack of k.d.f. cartons over a bottom oversize corrugated paper cap sheet; means for folding the portions of said capsheet that extend beyond said stack against said stack; means for placing said stack under pressure; means for positioning overlength corrugated paper reinforcing and protective members against predetermined portions of said stack while it is under partial pressure, upon portions of which boards are placed at one end of the stack; means for passing metal straps around said stack while it is under pressure, each said strap passing longitudinally across a said board; means for securing the ends of said strap together tightly to form a bale while said stack is under pressure; and means for releasing the pressure on said bale.

4. In a device for making a self-palletized package of k.d.f. corrugated cartons, the combination of means for stacking k.d.f. cartons; means for holding said stack at an elevated height while applying a stiff oversize locking sheet beneath the bottom of the stack, said locking sheet having flanges shorter than the height of said stack that lie against the edges of the end cartons; a press; means for moving said stack on its said locking sheet into said press, and means in said press for baling said stack and said locking sheet together by metal band means.

5; A device for making a self-palletized package of k.d.f. corrugated cartons, comprising: means for stacking k.d.f. cartons; means for holding said stack at an elevated height while applying an oversize cap sheet beneath the bottom of the stack; means for folding the portions of said cap sheet that extend beyond said stack against the edges of the end cartons; a press; means for moving said stack on its said cap sheet into said press; means for guiding the placing of additional protective members on said stack while it is in said press, said protective members also providing bases and locating means for pallet boards against one end of said stack; means for passing metal bands around said stack and longitudinally along saidboards; and means for securing the ends of said band together tightly to form a self-palletized bale.

6. In a device for making a self-palletized package of k.d.f. corrugated cartons, the combination of means for stacking k.d.f. cartons in two stacks; means for holding said stacks at an elevated height while applying a single oversize lower cap sheet beneath the bottom of the stacks; means for folding portions of said lower. capsheet that extend beyond said stacks against the common. 

